The Processing Flow and Production Process of Polar Fleece Fabric
The polar fleece fabric is soft, light, quick-drying, easy to wash, and can still keep out the cold when wet. Under the same conditions, it is twice the cold resistance of Merino wool and four times that of cotton. The lightweight fleece is easy to move and comfortable to wear.
The main component of polar fleece is polyester fiber (polyester). Its advantages are high strength, good elasticity, good heat resistance, good abrasion resistance, good sunlight resistance, corrosion resistance, lightweight, good warmth. Another outstanding advantage is that it is easy to take care of and can be washed.
If we want to better understand the characteristics of polar fleece fabrics, we need to clarify the following about the processing and production procedures of polar fleece fabrics.
cloth arrangement-dyeing vat-addition of raising agent-dehydration and drying-brushing-combing-shearing-polarizing particles-finished product shaping-packaging-warehousing.
1. Dyeing and finishing process and parameter design should consider maintaining the shape of hollow fibrils as much as possible and avoiding the shrinkage of the fiber cavity, otherwise, it is difficult to reflect the difference between special-shaped hollow fibers and conventional fibers.
2. When designing the process parameters of each process, it is necessary to ensure that the polar fleece has a thick and fluffy effect, increases the still air layer between the fibers, and improves the warmth, lightness, and softness of the fabric.
The special-shaped hollow polyester fiber fabric is dyed with high temperature and high pressure. The dyeing temperature is generally 120～130℃. Under the condition of ensuring the colorfastness, try to dye at 120℃, and the holding time should not exceed 30min. A phenomenon that affects the shrinkage of fibers.
During the dyeing operation, the vat volume should not be too large, try not to exceed 80% of the vat volume, so as to avoid prolonged stacking of the cloth in the dyeing vat.
2. Add fluffing agent
The method of adding a fluffing agent is divided into setting and fluffing agent and dyeing vat adding fluffing agent.
Adding the raising agent in the dyeing vat is to impregnate the raising agent at room temperature. In this way, when the raising agent is added, the cloth has low tension and is loose. The form of the special-shaped hollow fiber will not be changed too. What’s more, the auxiliary agent acts on the fiber for a long time, the effect is relatively uniform and has high production efficiency. Therefore, it’s better to add a fluffing agent into the dyeing vat.
The bristles use a mechanical straight needle to support the flat cloth surface, and the curved needle (starting needle) gradually grabs the fiber layers on the loop and continuously hooks the loop yarn to loosen the loop yarn to form independent fluff, feather, and cover. Fabric surface.
Because of the continuous hooking and pulling off the loop yarn by the bending needle, the fabric shrinks longitudinally and horizontally, the cloth body is thick, not easy to shed hair, the fluff is fluffy, and the added value of the fabric is increased.
The brush hair adjustment machine should pay attention to the tension and the raising rate (that is, the speed of the looper). The size of the tension determines the length of the hair, and the raising rate determines the thickness of the fluff.
The faster the needle covering speed, the looser the tension, the faster the needle starting speed, and the higher the raising rate. Conversely, the tighter the tension, the lower the raising rate.
The pre-shaped special-shaped hollow polyester fibers have large gaps, and the tension of the bristles is looser than that of conventional polar fleece, and the bristles can be lightly brushed. The bristle card clothing uses curved needle bristles with low density and good elasticity, which can easily hook off the hollow fiber, hook, and feather, reduce the probability of stretching and breaking the hollow fiber, and reduce the loss.
After brushing, the semi-finished product passes through the needle roller of the carding machine to comb and straighten the messy hairs. The grains are easy to agglomerate.
After weaving, untwisting, or brushing, the length of the pile fiber on the surface of the pile fabric is different. It is necessary to cut the pile into upright and neat short hair or cut the long hair to make the pile surface flat. The length of the shearing directly determines the size of the polar particles. The longer the hair, the larger the particles, and the fluffy the polar style. The more static air content in the shaped hollow polyester fiber, the better the warmth retention.
Therefore, to produce ultra-fluffy-shaped hollow polyester fiber polar fleece, the shearing hair must be longer, and the floating hair will be reduced, and the shearing loss will be reduced. But the shearing hair should not be too long, otherwise, there will be too much-floating hair on the cloth surface, and the rough surface will be uneven, which will make the particles formed after the polarizing blur, not smooth, and affect the beauty.
When shearing, adjust the angle of the triangular knife and the round knife according to the thickness of the cloth, so that the cut fluff is upright and without lodging, so that the fluff has free space to entangle and contract with each other when flicking, forming full and fluffy particles, otherwise it will form The particles are relatively flat and not fluffy.
6. Polar particles
Polar particles are fabrics that are mechanically turned and blown by hot air, so that the fluff and fluff are intertwined, granulated, and contracted.
There are currently two types of shakers: tension-free shakers and jet continuous shakers.
The tension-free polar bucket is a traditional method of polarizing. After shearing, the cloth head needs to be cut. The polarizing particles are all manually held and stretched, which is high loss and labor-intensive. The tension-free fleece bucket is heated by steam, dried by hot air, and cooled by cold air.
The jet continuous anti-shrinking machine is heated by hot air and cooled by cold air. After shearing, there is no need to cut the cloth head. The cloth is directly fed into the jet-flow continuous polarizing shrink-proof machine through the cloth guide wheel. The cloth is cyclically rotated in the polarizing machine, and the hot air blows, oscillates, and frictions to form particles.
The polar fleece is heated by direct steam, and its temperature cannot be set according to the process requirements. The high temperature will cause large shrinkage of the shaped hollow polyester fiber, reduce the hollow volume, and affect the hollow structure and the bulkiness of the polar fleece. Hollow fiber is suitable for the production of the temperature-adjustable jet-flow continuous anti-shrinking machine.
7. Finished product shaping
When the shaped hollow polyester fiber is shaped, the stretching tension should be small to reduce the probability that the shaped hollow fiber will make the hollow pipe narrow and long and the hollow wall will stick due to stretching, and avoid the phenomenon of falling hair due to excessive stretching and reducing the polarizing style. The final shape of the polarized cloth should not be set by the roller, otherwise, it will affect the fluffy feel of the polarized style.
As an expert in polar fleece fabrics for many years, QIKUN TEXTILE can give you some professional suggestions on the manufacture and design of fleece fabrics.
As an experienced fleece fabric supplier, QIKUN TEXTILE has accumulated many years of manufacturing experience in this field. We have a professional production team and a strict quality inspection system, which can control the quality of our products in an all-round way. At the same time, we can also develop effective solutions and thoughtful one-stop services for users. If you are interested in our fleece fabrics, please contact us immediately!